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Butler Personnel ParachutesP.O. Box 60981820 Loudon Avenue, N.W.Roanoke, VA 24017-0098

www.butlerparachutes.comPhone: 540-342-2501

FAX: [email protected]

Butler Personnel Parachute SystemsButler Personnel Canopies

Assembly and Packing Instructions

HX Series Canopiesand

Lopo Series Canopies

Document Number: 50-1011

Revision E

February 20, 2019

Butler Parachute Systems - Canopy Packing Instructions

Document Number: 50-1011 Revision E - February 2019Page • 2

Issue Description Date Approving Authority

0.1 Baseline Document 3/27/09 XX

1.0 Initial Release 2/12/10 Roberto Montañez

2.0 Revision A 2/12/10 Roberto Montañez

3.0 Revision B 10/15/13 Roberto Montañez

4.0 Revision C 11/4/15 Roberto Montañez

5.0 Revision D 2/1/18 Roberto Montañez

6.0 Revision E 2/20/19 Roberto Montañez

Title Butler Personnel Canopies, Assembly and Packing

The portion of the text affected by the changes to the preceding released document are indicated by a black vertical bar in the left outer margins of the page.

List of Effective Changes

10 .........................................6 11 .........................................6

Page Number Section Number


Document Number: 50-1011 Page • 3 Revision E - February 2019

Contents

Warranty for Emergency Parachute Systems ........................................................................ 4

Terms & Conditions of Warranty ............................................................................................. 4

1. Introduction ........................................................................................................................ 5

2. Service Life and Repack Interval ....................................................................................... 6

3. Rigger Responsibilities and Rating Limitations ................................................................. 7

4. General Methods ............................................................................................................... 7

5. Tools and Materials ............................................................................................................ 8

6. Common Assembly............................................................................................................ 9

7. HX-series Assembly .......................................................................................................... 12

8. Lopo Series Assembly ....................................................................................................... 17

9. Folding the Canopy ........................................................................................................... 20

10. Stowing the Suspension Lines ........................................................................................ 22

Appendix A. Deployment Diaper Installation ......................................................................... 25

Appendix B. Slider Installation ............................................................................................... 26

Appendix C. Canopy Operating Limitations........................................................................... 27

sinCe we have no Control over the aCtual Conditions of usage we make no guarantee, expressed or implied, that a paraChute system will suCCessfully save a partiCular individual regardless of CorreCt manufaCture, assembly, paCking and usage in any and all Conditions under whiCh it might be used.

warning



Copyright© Butler Parachute Systems, Inc. 2019

All rights reserved. No part of this manual may be reproduced except for personal use. The copyright and all other rights regarding the content of this publication, as well as images and logos, are held by Butler Parachute Systems, Inc.

Butler Personnel Parachute Systems, Inc. (hereafter referred to as BPS) manufactures the finest emergency parachute systems in the world. Accordingly, subject to the Terms & Conditions set forth below, we warrant that our emergency parachute systems are free from defects in materials, workmanship and design for a period of five years from the date of manufacture.

Warranty for Emergency Parachute Systems

Terms & Conditions of Warranty

This warranty excludes any condition that (in the sole opinion of BPS) has resulted from misuse, abuse, modification, improper maintenance, neglect, exposure to ultraviolet light, damage from aircraft parts and/or any other condition that is outside the realm of normal usage. Usage of this product in a manner that violates state or federal law is a misuse of the product and voids all warranties, express or implied. BPS shall not be liable in any manner whatsoever for damages related to the use of this product in an illegal manner.

This warranty excludes any condition related to color fastness, fading and/or the matching of any particular lot of materials with any color.

All BPS products have been thoroughly tested and found to be in conformance with all applicable FAA requirements for TSO C-23 certification in effect on the date of authorization. However, since we have no control over the actual conditions of usage, this warranty specifically excludes any guarantee, express or implied, that a parachute system will successfully save a particular individual in all conditions under which it might be used.

This warranty covers the product only when it is used in accordance with the manufacturer’s instructions and within the stated and/or placarded operating limits regarding maximum pack opening airspeed and maximum gross weight for the lowest rated component of each assembly. Failure to follow these guidelines for the use of the product voids any and all warranties.

This warranty does include any changes that may be required under BPS Service Bulletins or FAA Airworthiness Directives, if issued. It does not include changes or updates that are recommended but not required.

the warranties and agreements herein set forth are exClusive and are expressly in lieu of all other warranties and agreements, express, implied, or statutory. there are no implied warranties of merChantability, workmanship or fitness for a partiCular purpose.

The customer’s sole and exclusive remedy for any breach of this warranty is limited to repair or replacement of any BPS product deemed to be defective. BPS shall have no other liability for any incidental, consequential or punitive damages.



1. Introduction

These instructions do not constitute complete instructions for assembling and packing a Butler Emergency Parachute. This manual outlines only the procedures for assembling, flaking and folding a Butler Personnel Emergency Parachute canopy. You must also have the appropriate manual for the container you are servicing and the manual titled General Information for Parachute Riggers Servicing BPS Personnel Parachute Systems. You may need additional manuals to pack the parachute if it has options that require maintenance and service not covered in the manuals listed above. Contact Butler Parachute Systems if you are not sure you have the manuals you need.

The Butler Emergency Parachute is an important piece of survival equipment. Proper installation, maintenance and packing are necessary for the parachute to deliver the safety performance it is designed to provide. It is important that you become familiar with these instructions to properly install the components and fold the canopy. Improper installation of the components and improper folding of the canopy may result in failure of the parachute system during use.

The following symbols are used throughout this manual:

warnings indicate a procedure or situation that may result in seriousinjury or death if instructions are not followed correctly.

cautions indicate any situation or technique that will result in potential damage to the product, or render the product unsafe if instructions are not followed correctly.

notes are used to emphasize important points, tips, and reminders.

warning

Caution

warning

butler paraChute systems, inC. reserves the right to revise this publiCation without obligation to provide notifiCation of suCh Changes. butler paraChute systems, inC. does its best to provide Current and aCCurate information in this manual. however, butler paraChute systems, inC. reserves the right to Change any speCifiCations and produCt Configurations at its disCretion without prior notiCe and without obligation to inClude suCh Changes in this manual.

improper use or negligent Care of this equipment Can Cause serious injury or death.

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2. Service Life and Repack Interval

All personnel parachutes manufactured by Butler Parachute Systems, Inc. are manufactured and certified under the Technical Standard Order (C23) process of the Department of Transportation, Federal Aviation Administration (FAA). Our products have been sold all over the world, and thus may fall under many other sets of operating regulations. The following guidance is provided to determine the allowable service life and repack interval under the specific circumstances listed:

the following information is provided as guidanCe only.

• When used in civil aircraft in the United States of America, our products have a recommended service life of 20 years from the date it is placed in service or 25 years from the date of manufacture. However, this parachute must be inspected and repacked in accordance with the applicable Federal Aviation Regulations, every 180 days. If more than 180 days has passed since the last inspection and repack, then the parachute is considered unairworthy until such inspection is completed.

• When used in civil aircraft outside the United States of America, our products have a recommended service life of 20 years from the date it is placed in service or 25 years from the date of manufacture. The local regulations pertaining to parachute inspection and repacking (if any) may be applied, but in no case longer than two years between inspection and repack.

If the parachute equipment is subjected to any unusual or severe conditions such as dust, moisture, impact damage, etc., it should be serviced on a more frequent basis. Please review all information in the User Guide and service manuals before extending your repack cycle.



3. Rigger Responsibilities and Rating Limitations

We spare no effort in making our equipment the finest emergency parachutes available. However, parachute riggers in the field must also do their part to educate the user so he or she may fully benefit from the level of safety protection our systems offer. Parachute riggers should help the user understand his or her parachute and how to use it. We recommend that you become familiar with the User’s Guide and answer any questions the user may have. We also recommend that you allow the user to don the parachute and pull the ripcord before each repack.

All routine maintenance and minor repairs that do not affect airworthiness may beperformed by an FAA licensed Senior Parachute Rigger (or foreign equivalent) with the proper facilities and equipment.

major repairs or alterations that may affeCt airworthiness must be returned to butler paraChutes or a designated representative.

4. General Methods

Unless stated otherwise, secure all hand tacks and ties with a surgeons knot and locking knot.

All bartacks called for in this manual are 48-stitch type.

All directional references are as the equipment is worn by the user.

A canopy cloth pull test is recommended once every two years. A canopy cloth pull test is required at the ten and fifteen year anniversary of the date of manufacture. Follow the procedures outlined in PIA Technical Standard 108-1.

Always count your tools before and after you work on a parachute to ensure nothing is missing or left inside the parachute.

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5. Tools and MaterialsWe consider the following tools to be the minimum tools necessary to pack a complete emergency parachute system. While all the tools listed may not be necessary to perform the steps outlined in this manual, they are necessary to perform the packing service of a complete emergency parachute system from start to finish.

• Temporary pins with safety flag

• Pull-up cords – 50” minimum

• Packing weights – 4 minimum

• Line separator

• Packing paddle

• 9mm wrench

• Scissors & tacking needle

• Lite Super Tack cord (50 lb)

• 80 pound break tape (Mil-T-5661, Type 1, 1/4”)

• Lead seals and seal thread

• Stow Band (Rubber Band, 1 1/4” x 3/8”)

• Closing loop material* (225 pound braided Dacron cord)

Required for assembly of an HX-series high speed canopy.

• 6’ bodkin with hole for attaching tack cord.

• Mil-T-5038, T3, 1/2” x 10”

Additional tools required for packing a system with a deployment bag.

• 18” bodkin with 40” pull-up cord attached

• Locking pull-up cord with washer*

* 2 for two pin container - 3 for three pin container.

* If the system you are packing has a CYPRES AAD installed, you must use closing loops made with CYPRES approved material (408 pound, 1.7 mm Spectra cord).



6. Common AssemblyLine Continuity

Lopo 350 & hx-300 Lopo 450 & HX-400

18 172

6 10

1415

9 13

3

7 11

154

8 12

16

Lopo 550 & HX-500

HX-500/24

HX-600

1920 18 172

6 10 14

15

9 13

3

7 11 15

4

8 12

16 22 21 1920 18 1726

10 14

15

9 13

3

7 11 15

4

8 12 16

26

10

15

9

3

7 11

4

8 12

2324 1920

18171413 15 16

22 21

6.1

Tack* the riser below the link.

Figure-eight a piece of tack cord* through each group of the suspension line loops at the link and tie the lines together.

* one turn of lite super taCk (50 lb.) taCk Cord.

6.1 Tacking the risers.

do not tie any lines together from different riser groups.

Perform a continuity and four-line check on the canopy and connect the links to a tension board with the back line groups on the inside and the front line groups on the outside.

figure-eight knot

2

6 10

141

5 9

133

7 11

154

8 12

16

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6.2

The steering line is marked for the toggle location. Installing the toggle with the mark at the toggle grommet provides 2” of slack in the steering line*.

Tie an overhand knot to make a 2” loop with the mark at the end of the loop.

it is the responsibility of the rigger installing the steering line to ensure there is enough slaCk in the steering line to prevent tension on the steering line when the Canopy is inflated.

caution

*

6.2 Installing the steering line toggle.

mark

2”


6.5

Thread the steering line through the toggle grommet from the back and form a lark’s head knot.

6.3

Finger trap and tack the excess steering line no longer than 1/4” below the knot with 24/4 cotton thread.


6.4 Threading the steering line guide.

6.4

Thread the steering line through the steering line guide on the riser.



6.6

Pull the toggle down so there is no slack in the steering line to ensure there is a minimum of 2” [+/- 1/2”] of slack in the steering line.

6.6 Inspecting the steering line slack.

2”

6.7

Mate the toggle to the Velcro so the grommet on the toggle is on top of the grommet on the steering line guide.

Pickup the steering lines and ensure they run free-and-clear from the toggle to the cascade where it enters the suspension line. 6.7 Setting the toggle.



7. HX-series Assembly

7.1

Straighten the canopy apex.

Tie the vent lines with a piece of break tape* four-to-six inches from the top.

*80 pound break tape (mil-t-5661, type 1, 1/4”). 7.1 Apex tie.

make this tie as tight as possible.

7.2

The zip-strip bridle splits at one end with two looped ends.

Attach the zip-strip bridle to the apex with a lark’s head knot.

7.2 Installing the zip-strip to the apex.

if you are paCking a system that has a deployment bag, use the instruCtions outlined in the manual titled deployment bag assembly and packing instructions to install the bridle and zip-strip.

referenCe

Channel bridle - pn: 701060 zip-strip bridle - pn: 701097

aPeX tie



7.3

Attach the channel bridle to the zip-strip bridle with a lark’s head knot.

Do not tighten the knot as you must pass the break loop through the knot.

7.3 Attaching the pilot chute bridle to the zip-strip.

7.4

Cut two 1” slits in the mesh at the base of the pilot chute. Cut one slit on each side of the grommet tab.

7.4 Cutting the pilot chute mesh.

do not tighten the lark’s head knot.caution

Pilot chute center line looP

bridle

inside of Pilot chute

7.5

Thread the free end of the channel bridle around the bottom grommet strap on the pilot chute, and through the pilot chute center line loop.

7.5 Threading the channel bridle.



7.6 Installing the pilot chute.

7.6

Pass the pilot chute through the loop on the channel bridle to form a lark’s head knot.

7.7 Threading the break loop.

7.7

Thread the break loop material* through the lark’s head knot on the channel bridle, then through the apex lines and the zip strip lark’s head knot

* Mil-T-5038, T3, 1/2” x 10”.



7.8

Form a 2”* loop with the tape and tie with a square knot. Tie an overhand knot on each leg.

Tie an overhand knot on each free end of the tape.

Tighten the lark’s head knot on the bridle.

*measured distant when extended.

7.8 Tying the break loop.

7.9 Stowing the zip-strip.

7.9

Insert the 6’ bodkin through the channel on the pilot chute bridle.

Thread a piece of tack cord through the hole in the bodkin and through the tip of the zip-strip.

Pull the zip-strip through the channel.

be sure the zip-strip is flat and has no twists in it before you begin to thread it through the Channel.



7.10

Close the vent cap.

Tie the 4 center tie-tabs together with one turn-doubled, 3-cord (8/4) cotton thread.

7.10 Tying the center tie-tabs.

7.11

Tie the 4 top tie-tabs together with one turn-doubled, 3-cord (8/4) cotton thread.

7.11 Tying the top tie-tabs.



8. Lopo Series Assembly

if you are paCking a system that has a deployment bag, use the instruCtions outlined in the manual titled deployment bag assembly and packing instructions to install the bridle and zip-strip.

referenCe

pilot Chute bridle - pn: 701062

8.1

Tie the vent lines following the steps in Section 7.1.

Install the bridle on the apex lines using a Lark’s Head knot. Do not tighten the knot. Tack the knot so the bridle can float freely on the apex lines.

8.1 Bridle installation onto the apex.do not tighten the lark’s head knot.

caution



8.2

Cut two 1” slits in the mesh at the base of the pilot chute. Cut one slit on each side of the grommet tab.

8.2 Cutting the pilot chute mesh.

Pilot chute center line looP

bridle

inside of Pilot chute

8.3

Thread the free end of the bridle around the bottom grommet strap on the pilot chute, and through the pilot chute center line loop.

8.3 Threading the bridle.



8.4 Installing the pilot chute.

8.4

Pass the pilot chute through the loop on the channel bridle to form a lark’s head knot.



9.2

Flake the canopy with an equal number of gores on each side.

9.2 Flaking the canopy.

9. Folding the Canopy

Loosen the Rapide links* and retighten them hand-tight, plus one quarter turn with a wrench.

* genuine frenCh maillon rapide links are the only ConneCtor links approved for installation on butler produCts.

9.1

Position the slider approximately halfway between the canopy skirt and the risers. Check the continuity of the suspension lines and slider installation.

be sure the suspension lines run free and Clear through their respeCtive slider grommet in the same order that the suspension line is installed on the ConneCtor link.

Place the parachute face-down on the table and apply tension. Thoroughly inspect the entire parachute system for damage or wear.

if you find damage or wear on the paraChute system, you must stop. do not proCeed with paCking the paraChute. damage or wear that will effeCt the airworthiness of the paraChute must be repaired or replaCed before you paCk the paraChute.

it is the rigger’s responsibility to determine the airworthiness of the paraChute system. ContaCt butler paraChutes if you have questions regarding the airworthiness of the paraChute system.

warning

warning



9.3

Ensure that the slider is clear of the suspension lines and centered between the two line groups.

Pull the slider up the suspension lines and place it in the canopy wind channel under the top gore of the canopy.

9.3 Stowing the slider.

9.4

Dress the skirt of the slider.

Wrap a small packing weight around the suspension lines to maintain neatness.

Pull each section of the skirt out from between the suspension lines. While you are dressing the skirt, ensure that each slider grommet is seated against the stop ring*.

Stack the slider skirt in two groups with an equal number of skirt sections on each side of the suspension lines.

* the lopo series does not have a stop ring. seat the grommet against the Canopy skirt.

9.4 Dressing the slider skirt.



10.1

Dress the skirt of the canopy and fold it up and against the radial seam.

10.1 Dressing the canopy skirt.

10.2

Fold the canopy into fifths.

10.2 Folding the canopy.

after the Canopy is stowed in the diaper, you may adjust the width of the folds while paCking it in the Container for neatness and Canopy distribution.

10. Stowing the Suspension Lines

if you are paCking a paraChute equipped with a deployment bag, refer to the manual titled deployment bag paCking instruCtions for further instruCtion.stop



10.3

Release the tension and pull the lines up and on top of the canopy past the diaper.

10.3 Wrapping the diaper.

10.4 Closing the first locking stow.

10.4

Close the top locking stow with a loop of suspension line so it is facing away from the stow bands.

make the suspension line stow loops between 1” and 1 1/2” long.

10.5

Close the second locking stow following the procedure in 10.4.

Fold the slider skirt so it will be inside the diaper after all the locking stows are closed.

10.5 Dressing the slider skirt.



10.6

Close the last locking stow following the procedure in 10 .4.

10.6 Closing the remaining locking stows.

10.7

Stow the remaining suspension lines starting with the stow band closest to the first locking stow.

Leave approximately 20” of line unstowed.

10.7 Stowing the suspension lines.

For further instruction regarding packing the canopy into a container, refer to the appropriate instructions for the container you are packing.



Appendix A. Deployment Diaper Installation

Install the diaper on the outside of the front radial seam with the bottom edge of the diaper 3/8” (width of the binding tape) below the bottom of the skirt band.

Position the label facing down, and to the left.

Using a 304 or 308 zigzag stitch, sew directly down the chalk line starting at the bottom of the skirt band and ending 1/2” above the top of the diaper. Bunch the stitching together at both ends to lock the stitch.

Sus

pens

ion

Line

Label is not visible from outside

Stitch 1/2” beyond the diaper onto the radial reinforcing tape. Bunch the stitching to lock the stitch.

Start the stitch on the edge of the skirt band. Bunch the stitching to lock the stitch

Position the diaper 3/8” below the skirt band (the width of the binding tape).

Skirt Band



Install the slider so the grommet (smooth side) is facing down (toward the links) and the grommet washer is facing up toward the canopy.

Install the slider in the same sequential order as the suspension lines. Install the suspension lines on the canopy links as you install the slider. When you are finished with the installation, the slider should be centered between the two line groups.

Inspect the suspension lines and slider for continuity. Ensure that the suspension lines run free and clear through their respective slider grommets in the same order that the suspension line is installed on the connector link.

Slider runs free and clear of the suspension lines and is centered between the two line groups.

Grommet (smooth) faces down toward the links.

Washer (rimmed) faces up toward the canopy.

Appendix B. Slider Installation



Appendix C. Canopy Operating Limitations

* knots equivalent airspeed: the calibrated airspeed corrected for adiabatic compressible flow for the particular altitude.

knots indicated airspeed: the speed shown on an aircraft’s pitot-static airspeed indicator.

P/N Model Diameter Weight

MaximumPermitted

Gross Weight@ 150 KEAS*

MaximumRecommended


DemonstratedOverload

KIAS

TSOAuthorization

2101-1 Lopo 350 23’ 6.0 220 lb 175 lb 264 lb @ 180 KIAS C23d

2101-2 Lopo 450 26’ 7.0 285 lb 235 lb 345 lb @ 180 KIAS C23d

2101-3 Lopo 550 29’ 8.0 330 lb. 300 lb 420 lb @ 180 KIAS C23d

3101 HX-300 20’ 5.8 250 lb 160 lb 300 lb @ 180 KIAS C23d

MaximumPermitted


MaximumRecommended


3102 HX-400 23’ 6.4 333 lb 225 lb 400 lb @ 180 KIAS C23d

3103 HX-500 26’ 7.9 350 lb 280 lb 450 lb @ 205 KIAS C23f

3106 HX-500/24 26’ 8.5 416lb 280 lb 500 lb @ 180 KIAS C23d

3104 HX-600 28’ 9.1 500 lb 340 lb 600 lb @ 180 KIAS C23d

butler paraChute systems, inC.1820 loudon avenue, n.w.

p.o. box 6098roanoke, va 24017-0098

telephone: (540) 342-2501 fax: (540) 342-4037e-mail: [email protected]

web site: www.butlerparaChutes.Com

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